PDF Instruction Manual Cat Bucyrus 150-B Shovel & Dragline - 1 MB
This instruction manual covers the Cat Bucyrus 150-B, a versatile machine that can be configured as a shovel or a dragline.
It provides operators and maintenance crews with fundamental information on assembly, operation, and upkeep.
This historical document is invaluable for anyone operating or restoring one of these classic pieces of earthmoving equipment.
Ensure safe and proper handling with this comprehensive guide.
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BI05554
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BI05554
BOOM ANGLE INDICATOR
The Boom Angle Indicator mounted on the right side of the boom foot is
a simple device for indicating the angle the boom makes with the true
horizontal. A plate, showing angle in degrees" is bolted to the right
side of the boom. A pendulum pointer suspended from one end hangs free.
When the boom is parallel with level ground the pendulum would indicate
zero degrees. As the boom is raised ,the angle indicated by the pendulum
increases.
CONSULT MACHINE SPECIFICATIONS FOR CORRECT OPERATING RADIUS.
For successful operation of machines with dragline type booms it is
necessary to operate well within the stability of the machine. The
machine specifications, included with these instructions, tabulate
permissible bucket size or maximum suspended load (bUCket and contents)
for all lengths of booms at various operating radius. The operating
radius means the distance of the suspended load from the center of
rotation when the machine is on firm level ground.
SET BOOM ANGLE WITH MACHINE ON FIRM, LEVEL GROUND.
When the machine first goes into operation the correct operating radius
should be determined, taking into consideration the weight and size of
the bucket used and the weight and condition of the material being
handled. Wet material weighs more than the same material dry. With
the machine on firm, level ground, measure off the radius determined
and raise the boom until the load is suspended at the correct radius.
The boom angle indicator will then show the true angle of the boom
with the horizontal.
WATCH BOOM ANGIE INDICATOR AT .AU.. TIMES.
While the machine is working, watch the boom angle indicator and if, at
any time, due to working on a grade or soft footing, the indicator
shows an angle less than that determined when the machine was on level
ground, raise the boom until the indicator shows an angle equal to, or
greater than, that shown when on level ground. Failure to do this
means that the machine is being operated in excess of its ratings and
damage may result.
CHANGE BOOM ANGLE IF BOOM LENGTH OR IOAD IS CHANGED.
If the length of boom is changed or a different bucket is used, or if
the nature of the material handled is such as to change the weight of
the loaded bucket, a new operating radius must be determined and a new
setting for the boom angle indicator determined.
Section X-700
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BI05554
INSTRVCTIONS rO,f TAKING UP BeARING WEIIR
I. IJECKE/ISE THICKNESS OF SHIMS 'AI' TO OIJT.tI/N ~ ~VNNIN'
C'~EJ4,eApcE.
2. AD.D .$I-IIMS (/-2-3-4) tlNOG.e ~,:r.s AT 'x" GQVAl.
REIY1DVED rli!.(M' 51Y/.#I:;q ":
ro rN/CKNtESS
NOTE: SHIMS (/-2-3-4) A~E' rU/lOJISN£J) WlrH 'TOOlS Alii/) SUPPl.IES UNIT:
HOIST BEARING CAP SHIMS
Revised July, 1964
Ref. Drawing 403782
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NOTE: BEARING INSTRUCTION
PROCEDURE FOR: ASSEMBLY
1ST. INT.SHAFT BRGS.(PC.MK. 93-86)
2ND. INT.SHAFT BRGS.(505-506) "---:-.,. - -.",-_. -'-' '-'~
TYPICAL PROCEDURE: F86-- -- ~.iEl
c
n
I. ROTATE SHAFT ASSEMBLY (499) ___+--.- ~ ~.~ ~~:~ -\ r --- - , - - ,~- -- . - '
wHILE TAKING UP ON OUTER RACE \ ' : f~'i :~'
,', . "!I".. - ''IT
I. \ .1.'"
.' "~T1
1;'iJ.~ ~ 1\ _
F80 ... J CL ~ , d_ /
-
RETAINER (574) BY TIGHTENING ~ .!~- " ,
CAPSCREw (575) wiTHOUT SHIM PACK ~~~~=:::::," - - = . t j ,1t:.~ ,
IN PLACE. ~:~---...~ -<d~'c-l~:,:::~-
2. CONTINUE TIGHTENING CAPSCREwS ~-
F!l76 _ _ . -
UNTIL BEARING BIND SLIGHTLY.
3. MEASURE GAP AT BEARING RETAINER F!l78-___ 0 IL LE VE L
F!l77---__ CA PA CITY
(57 4 )• F!lOO-_ 35 GA LS.
4. INSTALL A NOMINAL SHIM PACK F76----_
F!l74--'--GE!:! .~
THICKNESS wHICH wiLL EQUAL THE F!57!5---' - -.-.----..
11
THE MEA SURED GA P PLUS .003 ~~6~ --.--- .--
F499 _ ~~I,7':s:~--====~~1 ------- F93
~ / / ~
(ALLOwABLE SHIM PACK TOLERANCE '-
.... 000) -- FI3
·-F78
-.002) F594
------F!l73
-------- ------ '-'FI7
//7I--.~U-, FI4
SwiNG MACHINERY -"rl-_ FI5
--
F!506 II\\!lIWIQ...'-l-' I ---. F2!1!1
REF.856286 10-70 F!588 ---.----------= t- --.- __ F585
F!584----
F!l86-----·---- --~---
~ ----...J+----...~-- .__ F582
, r-- F!l83
IIO-B 150-B 190-B F!l87 181 -W
!1::::VAZZ'2?ZZ'W
----- ----
AB2 u
1~~-~:6
-----.- -'AB 138
!.../p-/r~ .,.jJ
r:'·'·/"'.,.,I;:::;l;.,,~ /FI
/~~~ ~~-<:<"'~ ~",~:t"'~,r:R-~~--_---L , / / F6
,/ ,~.~,;,,\,>,,~~~\.,.~: , / F3
./
/ t~
~' ~'l
'[ .,~i:
t~;-.:j: / //
/
// lt~ ~ l~~:
~-T""';'<;~"-'''\~\--<''_' - .~-
L........:L~-'"-~_~_~_::..' ~
/
BI05554
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Collector rings of wound-rotor and synchronous to check the alignment after the machine BI05554 first
motors must be kept clean and polished. Ordi- goes into service and at increasingly greater in-
narily the rings will require only occasional wip- tervals thereafter until it is definitely established
ing with a piece of canvas or non-linting cloth. 1£ that the alignment has not changed.
the rings become worn or pitted so that excessivc
The first step in checking alignment of a motor-
sparking occurs, grind or turn them to restore
generator set consisting of two or more units
a smooth and true surface. Be sure all dust and
all coupled with solid, flanged couplings, is to
dirt is blown out of the spaces between the collec-
loosen all bolts and remove all but two diamet-
tor rings.
rically opposite bolts in each coupling. Next,
Collector ring brushes must move freely in the use jacking bolts to force the coupling halves
holders and make firm contact with the rings. far enough apart to permit inserting feelers be-
Check the brushes frequently to see that they tween the coupling faces. Always open up the
are not stuck in the holders. New brushes couplings next to the two-bearing unit (usually
should be ground to perfect fit with fine sand- the driving motor) first, and do not open up
paper. Maintain the brush spring tension at a the couplings too far, because the total end
pressure of from 2 to 3 pounds per square inch play must be divided between the couplings.
for carbon or graphite brushes. When replacing After opening all couplings, remove the jack-
worn brushes, use the correct grade as furnished ing bolts from all couplings and check alignment
by Bucyrus-Erie Company. starting with one of the couplings next to the
two-bearing unit.
Induction motors of small and medium size are
usually furnished with ball or roller bearings. Check the coupling halves for parallel faces by
Induction or synchronous motors of the larger measuring the gap between halves with feeler
sizes may hav~ oil-lubricated sleeve bearings. gauges. Measure the gap at four points spaced
90 degrees apart around the coupling, then turn
Actual lubrication requirements of any particu- both shafts ~ revolution and again take the
lar motor or generator vary to a great extent four gauge measurements. Repeat this proce-
on the details of construction, therefore it is im- dure two more times, turning the shafts 1i
possible to give detailed lubrication instructions revolution each time, taking care to turn both
which will apply to all motors and generators. shafts the same amount, so that the relative
Manufacturers bulletins covering the electrical position of the coupling halves is not disturbed.
equipment are included with the instructions
furnished for the machine. Read the bulletin The measurements on the sides of the coupling
applying to the particular piece of equipment should check within 0.002 in. for all positions
for detailed maintenance instructions. but the top and bottom readings may show a
constant difference due to the tendency for the
shafts to drop slightly at the open coupling.
Couplings
The couplings used for connecting separate units Correction of vertical misalignment is obtained
of the motor generator set may be either of two by adding or removing shims under the frame
general types, depending upon the construction feet. Correction sidewise is obtained by remov-
of the motor generator set. Flexible couplings ing the dowels, loosening the foot bolts and tap-
are usually used where both units to be connected ping the feet until the desired movement is
have shafts supported at both ends. Solid (or obtained. Tighten the foot bolts before recheck:
rigid) couplings are used where one or both ing the alignment. After correct alignment is
shafts are supported at one end only. obtained drill new dowel holes and insert the
dowels.
Solid couplings are of the flanged type and con-
sist of two steel members rigidly bolted together. The flexible couplings used may be any of several
One half has a projecting ring on the face of the different types depending upon the manufacturer
flange and the other half has a corresponding re- of the motor generator set.
cess in the face of the flange. The fitted bolts
holding the coupling halves together permit no The "Fasts·' flexible coupling, used on some sets,
flexibility, therefore the coupling halves must be is not a universal joint and the same care must
very accurately aligned when assembling the be taken in alignment of the coupling as for the
coupling. The coupling was correctly installed at solid coupling. In addition to checking the gap
the factory but because of possible distortion in between coupling halves, check the hubs for con-
the supporting base, resulting from handling or centricity by pfacing a straightedge on the rims
from settling of the machine framework, it is well of the hubs. Insert shims, if necessary, so that
. .. .
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Keep the motor clean and free of dirt and oil by the case of large and important motors and BI05554
gen-
following the general instructions given for al- erators, by keeping them slightly warm at all
ternating current motors. times. Current at a low voltage can be passed
through the windings or electric heaters can be
If the compressor does not pump the required used with tarpaulins stretched over the motor or
amount of air without running excessively, check generator to maintain the proper temperature.
the air piping for possible leaks. If the cylinders
tack compression, examine the condition of the A systematic and periodic inspection of motors
valves and clean, if necessary, as described in the and generators is necessary to ensure best opera-
manufacturer's bulletin. CAUTION: DO NOT tion. Some machines are installed where condi-
ATTEMPT TO REMOVE THE DISCHARGE tions are ideal, where dust, dirt and moisture are
VALVE CAPS UNTIL THE AIR HAS BEEN not present to an appreciable degree; but most
BLED FROM THE SYSTEM. motors are located where some sort of dirt ac-
cumulates in the windings, lowering the insula-
The motor starting switch is provided with ther- tion resistance and cutting down creepage dis-
mal overload relays to protect the motor against tances. Stone or coal dusts are highly abrasive
overheating. If the overload relays continually and actually cut the insulation in being carried
open the magnetic switch, examine the compres- througl> by the ventilating air. If conditions are
sor for hot bearings or stuck valves. DO NOT extremely severe, open motors and generators
REPLACE THE RELAY HEATERS WITH may require a certain amount of cleaning each
HEATERS OF LARGER SIZE. day. For less severe conditions weekly inspection
and partial cleaning is sufficient. Most machines
Short circuit protection is obtained by the use require a complete overhauling and thorofigh
of a circuit breaker or fuses in the supply line. cleaning about once a year. .
Other motors may be connected to the same cir-
cuit breaker; therefore, in case the breaker opens, The best method for cleaning the insulation is air
investigate all circuits to determine the cause of at low pressure. The Bucyrus-Erie Company
the trouble before resetting the circuit breaker offers a portable blower delivering a good volume
or replacing· the fuses. of air at the correc~ pressure which is very con-
venient for the periodic cleaning of insulation.
The Care of Motor and
Generator Insulation
The following instructions regarding the care
and maintenance of motor and generator insula-
tion are of the utmost importance and should be
followed very carefully in order to obtain the
best results and continuous service from your Once each week, or oftener if required by ex-
machine. In the care of electric motors and gen- tremely dusty conditions, blowout the accumula-
erators, the feature having the greatest influence ted dust and dirt in the windings. Oil or grease
On operation, life and general well-being is the is extremely detrimental to the insulation and
care given insulation. must not be allowed to remain on the windings.
Wipe off any accumulation of grease and clean
Motors and generators that have been long in with carbon tetrachloride. Be sure there is good
transit in moist atmosphere, or have been idle ventilation, because the fumes are dangerous.
for an extended period without heat to prevent
the accumulation of moisture, should be If small cracks appear in the iRsulation, ap{>ly a
thoroughly dried out before being placed in serv- coat of insulating varnish after thoroughly clean-
ice. Machines may also become wet by accide'.1t, ing the winding. Suitable varnish for this pur-
Or they may "sweat" as a result of a difference pose may be obtained from the nearest dealer or
in their temperature and that of the surroumling the electrical equipment manufacturer. On most
air, just as cold water pipes "sweat" in warm, motors and generators, windings are accessible,
humid atmosphere. This condition is very in- and the air can be properly directed to prevent
jurious and should be prevented, particularl}4 in damage to them.
III
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BI05554
INSTRUCTION lOOK
AXIAL FLOW FANS 1110-2
mineral grease of about #1.1/2 to #2 consistency should be motor shafts are parallel and belts are perpendicular to the
used. The grease should be free of abrasive fillers and highly shaft. A straight edge or taut cord may be used to line up the
resistant to oxidation. When fans are operating at ele"'ated sheaves. Belts should be under light tension and should feel
temperature (166 F or highed, silicone or lithium soap base "live" when thumped. Belts should deflect slightly under light
grease should be used. This high temperature grease should pressure. To remove belts, loosen belt adjustmenL
have a breakdown point above 350 F.
WHEEL ROTATION
DRIVES Wheel rotation is shown by direction arrow on the wheel.
Sheaves should be firmly locked in position and the key Should this arrow become obscured, direction of rotation and
should fit tightly. Alignment is correct when the fan and air flow may be determined as indicated by the diagram.
METHOD OF DETERMINING AIR FLOW AND ROTATION
ROTATION
I
I
I
I
I
I
- - - - - - - - - _.J
r----,
I I
----,I
I I
I I
I I
I I
I I
'------ oJI
CAUTION: If it should become necessary to remove the fin wheel from shift. the wheel should be carefull, mlrked, so thlt the Ilr flow flce
of the wheel blldes Ire repllced on the shift. In the corred direction of the air flow.
TEMPERATURE LIMITS PRE-OPERATING CHECK
Before putting the fan into operation, remove the shipping
TEMP. LIMITS (DEG.F>
TYPE FAN ARR. TYPE WHEEL CONSTRUCTION Min. Mn. wire holding the wheel and turn the wheel by hand to be sure
lubeaxial 9 Aluminum Standard -20 +150 it is not rubbing against the casing. Check for tightness of
Tubeaxial 9 Steel Standard -20 +165
Tubenial 9 Steel 350 F -20 +350 wheel on shaft. Factory mounted motors on Arr. 9 fans may
Tubenial 9 Steel 600 F -20 +600 shift during shipment. Therefore, V·belt alignment should be
Corrosive
Tubenial 9 Steel Protective CoaUnl -20 +165 checked. Be sure that belts are not rubbing against the in·
Tubenial 3 Stl or Alum Standard -20 +150 ternal belt guard. Check belt tension and, if required, adjust
Vane or 4 Stl or Alum Standard -20
':'ubenlal +100
by means of the four adjus.ting bolts on the motor base plate.
Vanenial 9 Stl or Alum Standard -20 +150
Spra,booth 9 Aluminum Standard -20 +150 If, during operation, the belts should stretch beyond the limits
Spra,booth 9 Steel Standard -20 +165 of the adjustment bolts, the assembly may be raised by reo
RENIWAL PARTS positioning the holding bolts in the next higher bole.
Check wheel rotation when starting the unit to be sure it
When continuoue ran operation Ie vitll it is recommended
conforms to the direction arrow on the wheel. Make sure air
thlt ~plre parts such as bearings, V·belts and, In some casee,
flow conforms with direction arrow on casing.
whcch be kept on hand for emergencies.
-2- X-2809
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BI05554
mainin« mtdamaged metal, arid pitting is -likely
to increase progressively until the tooth surfaces
lE!'e' destiUred or severely damaged.
On the other had, with helical, herriqgbone
and spiral bevel gears, '. there is less·likelihPod of
destructive pitting. This is ·because eathi ,tooth
du.ring mesh makes contact along a slanted line
extending from root to tip~ This line cuts ,across
the pitch line,andaltllough pitting-may have
rflughened the area along the pitch line, the line
of contact always extends beyond this roughened
surface, and thus the load is carried on undam-
aged root and' tip ¥88S. Under such circum·
stances, pittin,may cease as .•sOon as the few,'
isolated high spots along the pitch line ha"e been
removed.
Pitting is more likely to occur on wide- than
narrow~faeedpan beeauee of the greater diffi·
culty in obtaining trueandUDifonn contact
occurs. As a result~ minute particles break away across the entire width of the· wide teeth. After
and leave small pits where high points or hard high points and hard spote break away" tle load
spots have been (Fig. 1). may be distributed sufficiently'well overtbe rest
The type of pitting described ordinarily occurs of the tooth surfaces so that the gears~y then
,'only where there is a low ratio of slide to roll. operate- without further, -damage. With ~orrect
Therefore~ in spur or helical gears, the action Lubrication, normal w~ may ultimatelyjpolish
occurs at' or near the pitch line, where sliding the surfaces to a smooth, lIDbrok.en finis~. This
is ata minimum. On other areaso£ the tooth sort of pitting is called correc.e· or ~ipient
surface the sliding action wears' away the high pitting'and is not serious. '
spots before pitting can OCCur. With worm and When pitting hecoJJleS!. progressivelyi worse
most hypoidgears, side slide predominates in all (Fig. 2) , a reductionaf load on the gears will
contact areas, and true pitting of the gear teeth
does not occur.
Although pitting is not a lubrication failure,
there is some experimental evidence that oil plays
a .part in the £ollowingmanner: As a result of
fatigue, microscopic surface fatigue cracks start.
These become filled with oil, and under the con-
tact loads existing between the teeth, hydraulic
pr~ssure is developed. The pressure tends to ex-
tend the cracks and eventually to push out small
particles of ~tal. This· hydraulic. action would
occur with any fluid.
With spur and bevel gears, as each tooth: puIfeI'
through' the center of. mesh,. the, entire load is
momentarilY·COncentrated on th~ pitch line. If the
area alopg the pitch line has already started to
pit, the load is further concentrated on the re-
X.2622
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BI05554
Twice a year, or when temperature changes make it necessary, drain the
propel gear case and cat drive gear cases immediately after propelling,
and fill with gear lubricant of correct grade. Reterto Lubrication
Manufacturers' Charts.
Note 6. SWing Roller Path and SWing Rack- Keep the roller path and swing rack
thinly coated with gear compound. Check daily. If dirt accumulates,
wash off the old lubricant and apply a fresh coat.
Note 7. Keep the steering clutches free of dirt, clay, etc. These clutches
must be kept clean as their return into the engaged position is by
spring action. ~ .
UPPER WORKS LUBRICATION